The woven portion of the exhaust manifold of my 1996 850 NA is completely frayed, I'm getting an exhaust leak and a rumbling (though not offensively loud) exhaust sound. So, time for a new exhaust manifold, I think. But looking at the rusty studs that hold the manifold to the engine, I'm wondering how much of a hassle it's going to be getting those things out in one piece. (I'm just off a control arm project on my Saturn in which it came down to firing up a Sawzall to remove a bold, so I'm a little worn out on this.) Any predictions, advice? I'd love to hear about it.

 

What's the "woven" portion??? Are you referring to the flex piece? I thought that was part of the exhaust not the Manifold.

The night before you do the work, hit the studs with an excess amount of PB Blaster. Then do it again before you start the job.

I was recommended the same thing and when I replaced my exhaust mani last week in my '97 850 (183k miles), all the studs came out just fine. I did have 2 nuts that were seized onto the studs so I had to replace them with new hard ware. You should be able to get replacement parts from an auto store or order them from iPd.
Link to the stud, nut, and washer.
R Exhaust Manifold

Get the exhaust gasket from Snabb. It's SO much easier with their one piece gasket then Volvo's 5 piece gasket. Very worth the extra $10.
Stainless Exhaust Manifold Gasket